Toyota FJ Cruiser 2006-Up SetPart # 31922 Revision A 10-8-07 Step 1: Prior to Installation: A) Fit: Verify the fit of the flares to vehicle. (Some filing, sanding, or cutting may be necessary to ensure proper fit). B) Painting: (Optional) if paint is desired it must be done prior to installing flares on the vehicle clean outer surface with a good grade degreaser. DO NOT USE LACQUER THINNER OR ENAMEL REDUCER AS A DEGREASER. Wipe outer surface thoroughly with a tack rag prior to paint. Paint flares using a high quality enamel, or polyurethane automotive paint. (Application of a primer coat is optional) If painting edge trim (not recommended), use a flex additive. C) Performance: Using larger Tires may increase the area required to turn the vehicle. Some Tire/Rim combinations may require lowering bump stops and or installing steering stops to prevent tire from contacting flare. D) Exhaust System: Modifications may be necessary to maintain a minimum 4” clearance between flares and exhaust pipes. (Exhaust gases should not vent directly onto flares) E) Metal Protection: All exposed fasteners and bare metal should be treated with red oxide primer BEFORE installing flares. Spray inner fender wells with undercoating AFTER flare attachments have been completed. TOOLS FOR EASY INSTALLATION • • • • • • • • • • • • Pry Tool Flat Head Screwdriver Socket Wrench 10mm Socket 1/2" Socket 7/16” Socket Electric Drill 5/16” Drill Bit T45 Torx Bit Grease Pencil #2 Phillips Screwdriver Utility Knife or Cutting Tool NOTE: THESE INSTRUCTIONS INVOLVE CUTTING PARTS OF THE VEHICLE. IT IS IMPORTANT TO READ ALL INSTRUCTIONS PRIOR TO CUTTING AND INSTALLATION OF FLARES. 1. PARTS INCLUDED IN KIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Left Front Flare Right Front Flare Front Flare Inner Pieces Left Rear Flare Pieces (Main and Lower) Right Rear Flare Pieces (Main and Lower) Edge Trim (324 inches) Torx Screw (33 pieces) Small Washer (33 pieces) Hex Nut (33 pieces) “U” Clip (4 pieces) Pan Head Screw (4 pieces) #14 Hex Head Bolt (24 pieces) Christmas Tree Fastener (4 pieces) Plastic Grommet (2 pieces) Steel Bolt (4 pieces) Nylock Nut (4 pieces) Large Washer (8 pieces) 10. 11. “U” Clip 5. 3. Right Front Flare Left Front Flare 6. Right Rear Flare Pieces 12. Pan Head Screw 2. #14 Hex Head Bolt 4. Front Flare Inner Pieces Edge Trim 13. Christmas Tree Fastener 14. Torx Screw Steel Bolt Hex Nut Small Washer 16. 15. Plastic Grommet 9. 8. 7. Left Rear Flare Pieces 17. Nylock Nut Large Washer 6710 N. CATLIN AVE. • PORTLAND, OR 97203 • 503-283-4335 • 1-800-234-8920 (USA AND CANADA) • FAX 503-283-3007 FLARE INSTALLATION PROCEDURES Step 2: Edge Trim Installation (See Illustration #1) A) Peel two to three inches of red backing away from edge trim tape. Applying the adhesive side of the edge trim to the inner side of the flare, affix the edge trim to the top edge of the flare. See Illustration #1. B) Press edge trim into place along the top edge of the outer flare in one-foot increments, pulling red backing free as you continue to work your way around the top edge of the flare. Illustration #1 Step 3: Front Factory Flare Removal (See Photos #1 through #11) 1 Remove six bolts from wheel well using a 10mm socket. 3 Remove three plastic fasteners using a flat head screw driver or pry tool. 2 Remove two bolts connecting factory flare to rocker as shown (one plastic fastener removed in Step 3 is located here as well). 4 Using a utility knife, cut along seam connecting factory flare to rocker. Cut down to mud flap area. 5 Using a utility knife, cut splash guard flush with edge of sheet metal also. 6 Trim an additional 3/4” from rocker, so that end of rocker is within confines of sheet metal. NOTE: The Flare will cover this area to 1/4” from the door seam. 7 Cut front of factory flare along bumper, taking care not to cut bumper. 8 Trim remaining plastic flush with bumper. 10 9 Trim plastic tab along seam. Remove mud flap bolts as shown (2 places). 11 Remove third mud flap bolt, and remove mud flap. Step 4: Front Flare Installation (See Photos #12 through #21) 12 Prior to paint, use a drill with 5/16” bit to drill holes at indents in pockets (8 places each flare). Drill from outside of parts. 14 Insert one Screw/Washer assembly through each pocket hole drilled in Step 12. 13 Slide a supplied Small Washer onto a supplied Torx Screw. 15 Place a supplied Hex Nut on the backside of the screw and tighten using a 1/2" socket and T45 Torx bit. Repeat for all pockets. 17 16 Holding Front Inner Piece on front of wheel well next to bumper, use a grease pencil to mark two clip locations. 18 Slide supplied “U” Clips over holes drilled in Step 17 (2 places). 20 Position Flare on fender. Install five supplied #14 Hex Head Bolts. Do not tighten. NOTE: It is helpful to install one of the top bolts first. Remove Front Inner Piece, and drill two 5/16” holes on marks made in Step 16 (2 places). 19 Position Inner Front Piece on vehicle, aligning holes in part with holes in clips installed in Step 18. Install supplied Pan Head Screws. 21 Install one supplied Christmas Tree Fastener in top hole. Check that edge trim is seated correctly, then tighten all bolts. Step 5: Rear Factory Flare Removal (See Photos #22 through #34) 23 22 Remove two bolts from mud flap. Using a 10mm socket, remove six bolts. 25 24 Using a pry tool or flat head screwdriver, remove one plastic fastener. 26 Remove bolt from mud guard located inside wheel well. Remove one plastic fastener from mud guard. 27 Pull back rear plastic panel to access bolt inside. Plastic clips will release, making a popping sound. 28 Remove bolt located behind rear plastic panel. NOTE: if the socket does not fit in the enclosed space, a Phillips screwdriver will work. 29 Remove 10mm bolt to remove mud flap completely. 30 31 Remove bolt from underside of factory flare (behind panel). Pry flare from fender, releasing plastic Using a pushing motion to engage clips, replace rear plastic panel. clips. 32 33 At front of wheel well, use pry tool or knife to pry plastic grommet from sheet metal. Discard grommet, leaving a square hole. Cut along rocker panel so that it is trimmed flush with sheet metal. 34 Remove last bolt holding the rear flare on, at the front of the wheel well. Remove flare. Step 6: Rear Flare Installation (See Photos #35 through #44) 34 Prior to paint, use a drill with 5/16” bit to drill holes at indents in pockets (8 places Right Main, 7 places Left Main, 1 each Lower Rear). Drill from outside of parts. 36 Insert one Screw/Washer assembly through each pocket hole drilled in Step 34. 35 Slide a supplied Small Washer onto a supplied Torx Screw. 37 Place a supplied Hex Nut on the backside of the screw and tighten using a 1/2" socket and T45 Torx bit. Repeat for all pockets. 38 Install a supplied plastic grommet in square hole at front of wheel well. 40 Align the holes in the Rear Main Flare with the holes in the Lower Rear, slide Bolt/Washer assembly through (2 places). 42 Position Flare on fender. Install six supplied #14 Hex Head Bolts. Do not tighten. NOTE: It is helpful to install one of the top screws first. 39 To attach Rear Main Flare to Lower Rear, slide a supplied Large Washer onto a supplied Steel Bolt. 41 Slide a supplied Large Washer onto backside of bolt, and thread a supplied Nylock Nut onto bolt. Using a 10mm socket and 7/16” wrench, tighten bolts. 43 Install one supplied Christmas Tree Fastener in top forward hole. Check that edge trim is seated correctly, then tighten all bolts.
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